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t CoolWave Applied Curing System Ten-Inch Lamphead Customer Product Manual Part 775160B Issued 6/03

To order parts call 866-885-1212. For technical support call 800-524-1322. This document is subject to change without notice. Check http://emanuals.nordson.com/uvsystems for the latest version.

NORDSON CORPORATION  AMHERST, OHIO  USA Address all correspondence to: North American Sales and Service Nordson UV Systems Inc. 555 Jackson Street Amherst, OH 44001 United States Tel: (440) 985-4592 (800) 717-4228 Fax: (440) 985-4593 Email: [email protected] Website: www.uv.curing.com

Nordson Corporation welcomes requests for information, comments, and Trademarks inquiries about its products. General information about Nordson can be found on the Internet using the following address: Nordson and the Nordson logo are registered trademarks of Nordson http://www.nordson.com. Corporation. Notice CoolWave is a trademark of Nordson Corporation. This is a Nordson Corporation publication which is protected by copyright. Nylok is a registered trademark of Nylok Fastener Corporation. Original copyright date 2002. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice.

Part 775160B E 2003 Nordson Corporation Table of Contents i

Table of Contents

Safety...... 1-1 Installation...... 3-1 Introduction...... 1-1 Introduction ...... 3-1 Qualified Personnel...... 1-1 Inspection and Packaging ...... 3-1 Intended Use...... 1-1 Mounting Guidelines ...... 3-1 Power Supply ...... 3-1 Regulations and Approvals...... 1-1 External Blowers - Cooling Air ...... 3-2 Personal Safety ...... 1-2 Lamphead ...... 3-2 Ultraviolet ...... 1-2 Shielding ...... 3-2 First Aid ...... 1-3 RF Detector ...... 3-3 Microwave Radiation ...... 1-3 Electrical Installation Guidelines ...... 3-3 Power Line Connections ...... 3-3 Gas ...... 1-4 Input Power Configuration ...... 3-4 High ...... 1-4 Power Source ...... 3-4 High Voltage ...... 1-4 Environmental Operating Conditions ...... 3-4 Bulbs ()...... 1-5 Network Connections ...... 3-4 Network Connectors IN1 and OUT1 ...... 3-4 UV Curable and Products ...... 1-5 Input Connector TB2 ...... 3-6 Safety ...... 1-5 Remote Power Level Control ...... 3-7 Action in the Event of a Malfunction...... 1-5 Start-Up Timing Diagram Safety Precautions While Servicing ...... 1-6 for Remote Input Contact Closures ...... 3-7 Control System Cleaning ...... 1-6 Output Connector TB1 ...... 3-8 High Voltage Connections ...... 1-6 Cable Connections ...... 3-8 Lamphead ...... 3-8 Cabinet Cooling ...... 1-6 RF Detector ...... 3-8 Disposal...... 1-6 Main Control Board Standard Configurations . . 3-9 Safety Symbols...... 1-6 Main Control Board Dip Switches ...... 3-10 Dip Switch Configurations ...... 3-11 Description...... 2-1 Power Supply Address Switch ...... 3-12 Standalone Units ...... 3-12 Introduction ...... 2-1 Networked Units ...... 3-12 What is UV Curing? ...... 2-1 How Does it Work? ...... 2-1 Operation...... 4-1 Introduction ...... 4-1 System Components ...... 2-2 Display and Controls ...... 4-1 Reflectors ...... 2-4 Display Messages ...... 4-2 Fault Messages ...... 4-3 Resetting a Fault ...... 4-3 Lamp Start-Up Timing Diagram for Remote Input Contact Closures ...... 4-4 Startup ...... 4-5 Locally Operated Units ...... 4-5 Remotely Operated Units ...... 4-8 Shutdown ...... 4-9

E 2003 Nordson Corporation Part 775160B ii Table of Contents

Maintenance and Repair...... 5-1 Maintenance and Replacement Schedule . . . . . 5-1 Replacement Procedures ...... 5-3 Preparation ...... 5-3 Bulb Replacement ...... 5-3 Reflector Replacement ...... 5-4 Remove the Reflectors ...... 5-4 Install the Reflectors ...... 5-5 Internal Component Replacement ...... 5-6 Pressure Switch ...... 5-8 Light Detector Board ...... 5-9 Starter Bulb ...... 5-9 Magnetron ...... 5-10 Fuse Replacement ...... 5-12 Air Filter Cleaning and Supply Cooling Fan . 5-12

Troubleshooting...... 6-1 Introduction ...... 6-1 General Troubleshooting ...... 6-1 Troubleshooting Bulb Problems ...... 6-4 Troubleshooting Curing Process Problems . . . . 6-4

Parts...... 7-1 Introduction ...... 7-1 Using the Illustrated Parts List ...... 7-1 Lamphead ...... 7-2 Power Supply and RF Detector ...... 7-4 CoolWave Cables ...... 7-6 Recommended Spare Parts ...... 7-7

Specifications...... 8-1 Power Supply ...... 8-1 Lamphead ...... 8-2 Bulb ...... 8-2 RF Detector ...... 8-2 System Drawings ...... 8-4

UV Glossary...... 9-1

Part 775160B E 2003 Nordson Corporation Safety 1-1

Section 1 Safety

The equipment is not flame or explosion proof and Introduction is not designed for use in hazardous areas.

Read and follow these safety instructions. Task- Use of Nordson equipment in ways other than and equipment-specific warnings, cautions, and those described in the documentation supplied with instructions are included in equipment the equipment may result in injury to persons or documentation where appropriate. damage to property. Make sure all equipment documentation, including these instructions, is accessible to all persons Some examples of unintended use of equipment operating or servicing equipment. include: S All equipment is designed and manufactured to using incompatible materials International Safety Standards to ensure that the S making unauthorized modifications and safety of the operator is protected at all S removing or bypassing safety guards, shielding, times. or interlocks S using incompatible or damaged parts Qualified Personnel S using unapproved auxiliary equipment S operating equipment in excess of maximum Equipment owners are responsible for making sure ratings that Nordson equipment is installed, operated, and S using equipment in hazardous areas serviced by qualified personnel. Qualified personnel are those employees or contractors who are trained to safely perform their assigned tasks. They are familiar with all relevant safety rules and Regulations and regulations and are physically capable of performing their assigned tasks. Approvals

Make sure all equipment is rated and approved for the environment in which it is used. Any approvals Intended Use obtained for Nordson equipment will be voided if instructions for installation, operation, and service Nordson ultraviolet (UV) equipment is intended are not followed. specifically for integration into other machines and should NOT be operated as a standalone system Currently there are two organizations that set or without appropriate safety guarding, shielding, recommended guidelines for exposure to and interlocks. It is the responsibility of the occupational microwave , OSHA integrator and end user to ensure that the final (U.S. Department of labor, Occupational Safety and assembly fulfills all necessary legislation and is Health Administration - Directive 29cfr 1910.97) completely safe before operation. and ANSI (American National Standards Institute - Directive C95.1-1982). The ANSI directive, which This equipment is designed for the accelerated is more stringent and most commonly referred to, curing of UV inks, , and coatings. Do not states that individuals should not be exposed to use this equipment to cure alternative materials microwave radiation levels above 5 mW/cm2 at unless approved by the material supplier. 2.45 GHz on a continuous basis.

E 2003 Nordson Corporation Part 775160B 1-2 Safety

Personal Safety Ultraviolet Radiation To prevent injury follow these instructions. WARNING: Ultraviolet light is a form of S electromagnetic radiation and can be Do not operate or service equipment unless you harmful if exposure exceeds recommended are qualified. levels. Protect and skin from direct S Do not operate equipment unless safety exposure to UV light. All equipment or guards, light shields, doors, and/or covers are areas where UV light is used must be intact and automatic interlocks are operating adequately guarded, shielded, and properly. Do not bypass or disarm any safety interlocked to prevent accidental exposure. devices. Ultraviolet light is not capable of penetrating into S Keep clear of moving equipment. Before the body and interacting with internal tissues and adjusting or servicing any moving equipment, organs. shut off the power supply and wait until the The National Institute for Occupational Safety and equipment comes to a complete stop. Lock out Health (NIOSH) document Criteria for power and secure the equipment to prevent Recommended Standard... Occupational Exposure unexpected movement. to Ultraviolet Radiation (PB214 268) establishes S Obtain and read Material Safety Data Sheets guidelines for safe use. (MSDS) for all materials used. Follow the See Figure 1-1. Ultraviolet light is divided into manufacturer’s instructions for safe handling bands A, B, C, and V along with and use of materials. Always use vacuum UV. Although values for wavelength bands recommended personal protection devices. will vary depending on the source, the following S Make sure the UV area is adequately ranges may be used as a guide. ventilated. S Vacuum UV (100-200 nanometers) - absorbed by air and poses no danger to humans. S The UV equipment runs at extremely high S . Do not touch the UV lamphead UV-A (315-400 nanometers) - represents the face during operation or immediately after largest portion of UV energy and is most shutting off the equipment. responsible for aging and increased S pigmentation. UV-A is at the lower limit of To prevent injury, be aware of less-obvious sensitivity to the human . Referred to as far dangers in the workplace that often cannot be UV. completely eliminated, such as hot surfaces, S sharp edges, energized electrical circuits, and UV-B (280-315 nanometers) - most moving parts that cannot be enclosed or responsible for reddening and burning of the otherwise guarded for practical reasons. skin and damage to the eyes. S UV-C (200-280 nanometers) - filtered by S Always wear safety that offer UV ozone. Referred to as near UV. protection. S UV-V (400-450 nanometers) – visible UV S Never any part of the body to direct or indirect UV light. Exposure to UV radiation can result in S reddening of skin S headaches S sore eyes

Part 775160B E 2003 Nordson Corporation Safety 1-3

ULTRA X RAYS INFRA

VISIBLE

100 200 300400 500 600 700 800 900 1000 nanometers

FAR NEAR UV UV VACUUM UV U U UVCV UVA V B V

1500021A Figure 1-1 Ultraviolet Light Wavelength Bands It is very important that all precautions are taken to First Aid prevent all UV light, whether direct or indirect, from escaping the curing area. Exposure to UV light can Store-bought creams, lotions, or aloe can be be harmful to both eyes and skin. Use the applied to affected areas of the skin. Seek following table to determine the permissible immediate medical attention for skin and exposure time to UV light on unprotected eyes or direct UV exposure to the eyes. skin. Permissible Ultra Violet Exposures as Recommended by the American Conference of Government and Industrial Hygienists Microwave Radiation Duration of Effective Irradiance Exposure (Per Day) (E Micro Watts/cm sq) The lamp system utilizes high powered RF microwave energy generated by a 8 hours 0.1 magnetron to provide power to the UV 4 hours 0.2 lamp. This technology is identical to that of 2 hours 0.4 residential microwave ovens and like these ovens can be dangerous if misused. The 1 hour 0.8 lamp system is safe provided that the RF 30 minutes 1.7 screen and gasketing are intact. Any 15 minutes 3.3 damage such as rips or holes in the screen 10 minutes 5.0 may cause leakage of dangerous amounts of microwave radiation. The power to the 5 minutes 10 lamp is interlocked to the RF detector and 1 minute 50 will shut down if microwave leakage in 2 30 seconds 100 excess of 2 mW/cm is detected. Any excessive leakage will cause the system to 10 seconds 300 shutdown and the RF Detector fault will 1 second 3000 illuminate on the front of the power supply.

E 2003 Nordson Corporation Part 775160B 1-4 Safety

Ozone Gas High Temperature

Ozone (O3) is a colorless gas that is generated by the reaction of short- UV light (around UV curing systems generally run at 200-220 nanometers) with air, and it occurs extremely high temperatures. A sudden whenever high-energy electrical discharge is shock from touching a high temperature present. surface might cause an operator to jump or Ozone readily reverts to breathable when take his attention away from other potential mixed with atmospheric air. Ozone should be hazards. removed from the UV source via a sealed duct and discharged to according to local When shutting down UV equipment for regulations. The discharge location should be maintenance, allow the equipment to cool before away from pedestrian walkways and window beginning work, or wear protective gloves and openings and should be well above the average to prevent burns. human breathing height for the area. Regular ozone checks should be carried out every three months using an ozone meter. Recommended levels of ozone in the atmosphere High Voltage of a factory should not exceed 0.1 parts per million (PPM). This level is easily obtainable if The UV curing equipment operates at high voltages factory recommended exhaust rates are followed. up to 5000 Vdc. The system uses high-voltage, self-discharging capacitors. Once power to the Ozone has a very distinct, strong odor even at low power supply is shut off, the capacitors need levels. Immediate ozone checks should be made if 120 to 130 seconds to discharge. an operator can smell ozone. Most people can smell ozone at about one third the maximum If any electrical faults develop, the operator should: allowable 0.1 PPM level. 1. Switch the equipment off immediately. Ozone exposure will cause headaches and fatigue. It will also irritate the mouth and throat. 2. Make no attempt to service the equipment. Overexposure can lead to respiratory infections. 3. Call a qualified electrician, trained to service If ozone is detected, this type of equipment. 1. Shut down the UV system. 2. Check exhaust ducting for leaks. 3. Check the operator working area with an ozone meter. If a person is overcome by ozone, S Move the individual to a warm uncontaminated atmosphere and loosen tight clothing at the neck and waist. S Keep the individual at rest. S If the person has difficulty breathing, oxygen may be administered provided that suitable apparatus and a trained operator are available. S If breathing is weak or has ceased, artificial respiration should be started. S Seek medical assistance.

Part 775160B E 2003 Nordson Corporation Safety 1-5

Mercury Bulbs (Lamps) Fire Safety The bulbs used in UV lamp systems contain Under proper operating conditions, the surface mercury under medium pressure. Mercury is a temperature of the bulb is anywhere between toxic substance and must not be ingested or come 700-900 _C (1300-1700 _F), and the vapor gas into direct contact with the skin. Under normal UV inside the bulb is several thousand degrees operating conditions, mercury presents no hazard Fahrenheit. As a result, there is always a risk of as it is completely contained in the sealed fire, should any or flammable materials get tube of the bulb; however, it is strongly jammed under the lamp or in the lamp’s vicinity, or recommended that protective gloves and eye should there be any build-up of lint, dirt, or powder protection be worn when handling UV bulbs. within the lamp housing. These precautions should be followed when To avoid a fire or explosion, follow these disposing of UV bulbs: instructions. S Place the bulb in a rigid protective carton. S S Dispose of used bulbs through a local mercury Know where emergency stop buttons, shut-off recycling center. valves, and fire extinguishers are located. S S Wash your hands if a bulb breaks: mercury Clean, maintain, test, and repair equipment could come into contact with your skin. according to the instructions in this manual. S Do not store or handle bulbs near food or S Always keep a fire extinguisher approved for beverages. electrical equipment near the unit. S Nordson Corporation will dispose of UV bulbs Should a fire occur, the operator must: free of charge provided the customer covers all 1. Switch the equipment off immediately. shipping costs associated with returning the bulbs. For bulb disposal, please clearly mark 2. If possible, put out the fire with a fire on the all bulb containers AND shipping extinguisher. packages BULBS FOR DISPOSAL ONLY Bulbs should be shipped to: Primarc Action in the Event of a Bulb Disposal Department 2 Danforth Drive Malfunction Easton, Pennsylvania 18045 If a system or any equipment in a system malfunctions, shut off the system immediately and UV Curable Inks and perform the following steps: 1. Disconnect and lock out system electrical Products power. Some materials used in UV curable inks, 2. Identify the reason for the malfunction and adhesives, and are toxic. Before handling them, read the Material Safety Data correct it before restarting the system. Sheets provided by the manufacturer, use the recommended personal safety equipment, and follow the recommended procedures for safe use and disposal.

E 2003 Nordson Corporation Part 775160B 1-6 Safety

Safety Precautions While Safety Symbols Servicing The following safety symbols are used in this A qualified competent electrician must carry out all manual. The symbols are used along with electrical maintenance and servicing of this warnings to help you operate and maintain your equipment. equipment safely. Pay attention to all warnings and follow directions to avoid personal injury. WARNING: This equipment operates at high voltages up to 5000 volts dc and is WARNING: Mechanical or combined therefore potentially dangerous. The mechanical/electrical hazards. electrician servicing this equipment must take all precautions. WARNING: Electrical hazard WARNING: Isolate the equipment at the main, disconnect or lockout before removing any of the cover panels WARNING: Ultra violet light hazard

Control System Cleaning WARNING: hazard Keep all contactors and relays clean and free from dirt and dust. Check these regularly, particularly in extremely dusty or powder-charged working rooms. CAUTION: Equipment hazard High Voltage Connections Checks the high voltage connections within the equipment carefully to make sure that these do not become dirty or coated with powder or other possible conducting material. Clean them regularly, at least whenever the lamp is changed, possibly more often where a particularly heavily polluted atmosphere occurs. Cabinet Cooling Check the cabinet cooling fan at least weekly and kept clear of any material that might clog or stop its operation. The power supplies run warm and keeping them cool with proper ventilation will prolong their . Disposal Dispose of equipment and materials used in operation and servicing according to local codes.

Part 775160B E 2003 Nordson Corporation Description 2-1

Section 2 Description

Introduction How Does it Work?

This section provides a general overview of A microwave generator (magnetron) operating at ultraviolet (UV) curing and the components of the 2400 to 2500 MHz is used to excite a medium Nordson CoolWave ultraviolet microwave applied pressure mercury bulb installed in a lamphead. curing system. Ultraviolet light between 220 and 470 nanometers is emitted. The system is designed to cure UV inks, adhesives, and coatings for numerous industrial applications. Microwave energy from a magnetron is directed into a cavity containing the UV bulb. A screen The system consists of an individual 10-in. located at the opening of the cavity allows the UV lamphead, a corresponding fixed output power light to pass through while the microwave radiation supply, and an RF detector. Additional lampheads is contained. can be lined up end-to-end to form longer curing widths. In addition to ultraviolet light, the high-energy bulbs radiate heat. Therefore, a cooling system is Figure 2-2 and Table 2-1 illustrate and describe the incorporated to take away the excess heat and major components of a typical setup for a make sure that the bulbs and housings remain at CoolWave ultraviolet microwave applied curing an acceptable operating temperature. system. Your system may appear different depending on your application requirements. The unit is fitted with interlocks and safety faults that prevent the operation of the system in an unsafe condition and indicate any faults that might What is UV Curing? occur on the front panel of the power supply.

Ultraviolet curing is achieved by a chemical The power supply unit provides the high voltage reaction in special inks and coatings when intense supply for the lampheads and a control circuit to UV energy is focused on them. Curing efficiency interlock the lampheads with the machine. depends on UV power, coating weight, operation speed, type of substrates, material , and Light shielding is required to ensure the stray UV other factors. light and heat meet agreed safety criteria.

E 2003 Nordson Corporation Part 775160B 2-2 Description

System Components Refer to Table 2-1 and see Figure 2-2 for a description of the system components.

Table 2-1 System Components Item Component Description 1 Lamphead The lamphead consists of a bulb housing, UV bulb, wave guide, reflectors, light detector, starter bulb, and the magnetron assembly. The patented wave guide also couples RF energy to the bulb and provides cooling for the bulb. The lamphead reflects the emitted UV light onto the substrate. 2 Ultraviolet Bulbs Only genuine Nordson replacement bulbs should be used with this system. Alternative bulbs may damage the control or over- heat the reflector system. NOTE: The system warranty is void if genuine Nordson UV bulbs are not used. Contact a Nordson UV representative for ordering informationinformation. The system uses medium pressure mercury bulbs. The bulbs consist of high-purity quartz and have various fills including doped spectrally enhanced metal halide bulbs to produce light at different . Bulbs and controls are carefully matched to give optimum UV output and wavelength requirements. 3 Reflectors Refer to Reflectors on page 2-4 for more information. Elliptical shaped focus reflectors are used to guide the UV light in a tight band across the surface of the material being cured. The reflectors are manufactured from borosilicate , with a dichroic coating to give maximum UV reflectivity while minimizing radiation. NOTE: A wider band of light can be produced by using optional flood reflectors. Contact a Nordson UV representative for details. 4 Starter Bulb The starter bulb acts as the ignitor for the ultraviolet bulb. The starter bulb is powered with 220 Vac at the same time the magnetron is energized. After the UV bulb reaches full power the starter bulb turns off automatically. 5 Magnetrons The magnetrons are 3 kW, 2450 MHz ± 50 generators that convert high voltage electrical inputs to RF energy. The wave guide cavity is designed to couple the RF energy with the UV bulb, thus exciting a UV emitting plasma within the bulb. 6 External Blowers External blowers are used to cool the UV bulb and magnetron. The for Cooling lamphead requires approximately 350 CFM at 7 in. H2O of cooling air per lamphead in order to function properly. The external blowers must be sized appropriately to provide adequate cooling. 7 Power Supply The power supply is fully modular. One power supply must be provided for each lamphead. The power supply can operate as a standalone system or part of a Master/Remote circuit. Refer to Power Supply on page 3-1 for details. 8 RF Detector An RF detector monitors microwave energy levels. The system will shut down when RF levels above 5mW/cm2 are measured. Systems operated as standalone units require one RF detector per power supply unit. If multiple systems are networked then the master power supply unit must be connected to one RF detector. Refer to RF Detector on page 3-3 for details.

Part 775160B E 2003 Nordson Corporation Description 2-3

4 1

5

2

2 7 4 3

6

8 1

1500000A Figure 2-2 System Components (Typical UV Curing System Setup) 1. Lampheads 4. Starter bulb 7. Power supplies 2. Ultraviolet bulb 5. Magnetrons 8. RF detector 3. Reflectors 6. Tubing to external blowers for cooling

E 2003 Nordson Corporation Part 775160B 2-4 Description

The reflectors use different retaining brackets to Reflectors secure them in place in the lamphead. Figures 2-3 and 2-4 illustrate the curve in each reflector and the Two types of reflectors are available for the differences in their retaining brackets. lamphead: focus and flood. The flood reflectors produce a wider band of light.

1500089A 1500094A Figure 2-3 Focus Reflector and Bracket Figure 2-4 Flood Reflector and Bracket

Part 775160B E 2003 Nordson Corporation Installation 3-1

Section 3 Installation

WARNING: Allow only qualified personnel to perform the following tasks. Follow the Mounting Guidelines safety instructions in this document and all other related documentation. Power Supply WARNING: Due to the weight of the power supply, be careful when moving the unit. Introduction See Figure 3-1 for power supply dimensions and clearance requirements. This section contains the necessary information for S The power supply can be mounted on any installing the CoolWave system. Directions for horizontal surface. mounting and shielding are explained in general terms due to differences for each independent S Power supplies can be stacked up to five units installation. high but due to the weight of each unit (approximately 230 lb) it is recommended that they be stacked so they can be easily accessed for service. Inspection and Packaging S Leave at least six inches of ventilation clearance on all four sides of the power supply The Nordson CoolWave system has been carefully unit. tested, inspected, and packaged prior to shipping. S Blowers are mounted on the front and the rear Upon receipt, inspect the shipping materials and of the power supply and need to be free and components for visible damage. Report any clear of any obstructions. damage immediately to the shipper and to the Nordson UV systems engineering department. 465.50 mm (18.33 in) NOTE: When opening the packaging, please take 753.00 mm 452.80 mm care so that the packaging can be re-used to ship (29.65 in) (17.83 in) the unit to the next destination. Keep all packaging materials together and in a location that they will not get damaged.

256.30 mm (10.09 in)

152 mm (6 in) Ventilation Clearance on all Four Sides

1500001A Figure 3-1 Power Supply Dimensions

E 2003 Nordson Corporation Part 775160B 3-2 Installation

External Blowers - Cooling Air The cooling requirements for each lamphead is 350 cfm @ 7-in. H2O of static pressure. See Figure 3-2. Measure for the correct pressure at each lamphead at the port located at the top and center of the lamphead between the cable connections. The port can be exposed by Port to Measure removing the Phillips-head screw. Static Pressure

NOTE: If the top of the lamphead is not accessible, take a reading in the duct work immediately preceding the lamphead. In many applications there will be multiple lampheads obtaining their cooling air from a common source such as a plenum. 368.80 mm It is recommended that air flow adjustment (14.50 in) dampers be added to the ducting as close to the lamphead as possible.

Lamphead 200.50 mm 267.00 mm The lamphead mounting must include provisions (7.893 in) (10.512 in) for shielding the UV light and venting for the cooling air. Each application contains different constraints 1500002A and therefore requires custom design of enclosures Figure 3-2 Lamphead Dimensions and light shielding. Contact Nordson UV systems Note: The mounting holes on both sides of the lamphead engineering department for help with design. are the same. Figure 3-2 illustrates the physical dimensions of the lamphead. Install the lamphead screen (bulb end) Light Shielding 53.3 mm (2.1 in.) above the substrate for optimal S Provide adequate shielding of UV light. The focal positioning when using focus reflectors. lamphead must be enclosed such that no UV NOTE: If flood reflectors are used there is no set light is allowed to escape. focus distance. The screen to substrate distance is S Any louvered material used for exhausting must not as critical and can be adjusted to vary dosage. be of a light-shielding design. NOTE: Detailed dimensional data is provided for S If UV light does escape the operator must wear the lamphead on page 8-8 in the Specification approved UV-protective eyewear and section. long-sleeved clothing.

Part 775160B E 2003 Nordson Corporation Installation 3-3

19.1 mm RF Detector (0.75 in) Ø7.2 mm See Figure 3-1. (Ø0.28 in)

S One RF detector is normally required for every 16 networked units within one curing enclosure. 88.9 mm However, some applications and systems may (3.50 in) require a RF detector on each unit. Contact Ø4.0 mm your Nordson representative for more (Ø0.16 in) information. S 38.1 mm 12.7 mm Mount the RF detector so that the antenna (1.50 in) (0.50 in) 42.8 mm faces the lamphead screen and is between the (1.69 in) 14.0 mm operator and the lampheads or the lampheads (0.55 in) and any opening (the major source for RF leakage). S The minimum distance should be eight inches to prevent excessive heat on the detector surface. S Do not mount the RF detector directly below the lamphead. S For RF detector connections, refer to RF Detector on page 3-8.

8 in No RF Detector

12 in 1500059B Figure 3-3 RF Detector Dimensions and Mounting Guidelines

Electrical Installation Guidelines Power Line Connections Table 3-1 Transformer Taps Refer to Table 3-1. This unit is designed to Normal Voltage Transformer Voltage Range Tap accommodate a broad range of power line voltages + for both 50 and 60 Hz found around the world. The 480 /- 10% 432-528 480 + power line input is three phase, and the 440 /- 10% 396-484 440 transformer taps must be changed to select the 380 +/ 10 342-418 400 operating voltage range. The power supplies are - + designed to operate at /- 10% of the normal voltage for a given tap setting. Only the taps on the two identical power transformers need to be changed.

E 2003 Nordson Corporation Part 775160B 3-4 Installation

Input Power Configuration Refer to Table 3-2. Current ratings indicate current demand during normal full-power operation. Size supply wiring and circuit breakers or fuses to allow for heavy current draw during startup. Table 3-2 Power Line Current Line 60 Hz 50 Hz Amps @ Amps @ Amps @ Amps @ Amps @ Amps @ 380 Vac 440 Vac 480 Vac 380 Vac 440 Vac 480 Vac L1 14 13 12 16 15 14 L2 22 21 18 25 23 21 L3 13 13 12 16 15 14

Power Source Environmental Operating The customer power source must be wired in Conditions accordance with either the National Electric Code, Condition Specification Part I or the Canadian Electrical Code, Part I, or local codes. Up to 2000 meters (6561 ft) _ _ Connector P1 on the power supply is for Temperature 5-40 C (41-104 F) three-phase input power. A 600 Vac, 30 Amp twist Rh 80% up to 31 _C (88 _F), lock connector is supplied with the system for the decreasing lineraly to 50% power input. at 40 _C (104 _F). Measure the incoming power source voltage from the main power supply. Make sure that the power source voltage matches the transformer tap settings.

Network Connections Network Connectors IN1 and OUT1 NOTE: Equipment must be connected in See Figure 3-4 and refer to Table 3-3. Use the IN1 accordance with the NEC and local wiring codes. and OUT1 connectors (1) (shielded RJ45) to The power supply can be configured to form a connect multiple units in a Master/Remote fashion. network of up to 16 systems. The entire network The connection cable is commercially available and can be operated either from the master control unit should have a rating of CAT3 or higher. Repeat front panel or from a remote source. this for each unit

Table 3-3 IN1 and OUT1 Network Connectors Cable From To Length (ft) Part Network OUT1 connector IN1 connector of 6 775031 of a unit the next unit

Part 775160B E 2003 Nordson Corporation Installation 3-5 FAULT UNIT/ALL MASTER/SLAVE RE DET/NONE LOCK LOCAL

1

4 3 LOC LKOUT/NORMAL REM ANALG EN/DIS 2 FAULT ALL/UNIT SLAVE/MASTER 5 NONE/RE DET LAMP 6“/10”

7 LOC LKOUT/NORMAL REM ANALG EN/DIS 2 FAULT ALL/UNIT SLAVE/MASTER NONE/RE DET LAMP 6“/10” 6 8

7 LOC LKOUT/NORMAL REM ANALG EN/DIS 2 FAULT ALL/UNIT SLAVE/MASTER NONE/RE DET LAMP 6“/10”

7

1500004B

Figure 3-4 Network Connections 1. Network connectors IN1 and OUT1 4. Output connector TB1 7. DIP switches 2. Power supply 5. Power lines 8. Rotary address switch 3. Input connector TB2 6. Main control board

E 2003 Nordson Corporation Part 775160B 3-6 Installation

Input Connector TB2 Refer to Table 3-4 and see Figure 3-4.

The inputs from the TB2 input connecter (3) are designed for contact closure or an open collector output. With the exception of the 4-20 ma remote analog input, the input terminal voltage is 24 Vdc and will source about 8 ma. Table 3-4 Input Connector TB2 Pin Assignments Pin Function Remote Local Description 1 Common X X If this input is not interfaced to external equipment, a jumper must be installed. OOpeningpening this inputinput shuts down the powerpower 2 Machine Stop supply unit, sets the FAULT output, and causes the F STOP fault message to appear on the display. 3 Common X NA Remotely controls the power supply unit when operating in the Remote mode. A pulse or momentary contact closureclosure to thisthis inputinput 4 Remote Standby places the power supply unit in the Standby mode. (The Off/Reset contact must be closed) 5 Common X NA Remotely controls the power supply unit when operating in the Remote mode. This contact must bebe closedclosed forfor thethe lampheadlamphead to bebe turnedturned 6 Remote Off/Reset on. Opening the contact will turn the lamphead off and will clear a fault condition. 7 Common X NA Remotely controls the power supply unit when operating in the Remote mode. A pulse or momentary contact closure to this input turns tthehe CCoolWaveoolWave llampheadamphead to tthehe on state.state (Th(Thee 8 Remote Lamp On Off/Reset contact must be closed). The Off/Reset contact must be opened to turn the lamphead off. 9 Common X X If this input is not interfaced to external equipment, a jumper must be installed. OOpeningpening this inputinput shuts down the powerpower 10 External Interlock supply unit, sets the FAULT output, and causes the F LOCK fault message to appear on the display. 11 Chassis Ground X X Not Used 12 4-20 ma input X NA Remotely varies the lamphead output power or when the unit is in the Remote mode. The 0-10 Vac lamphead power varies from 25% to 100% power up to the front panel SETPOINT as the input current is varied from 4-20 ma or 0-10 Vac. NOTENOTE: If thithis iinput t isi used d tot vary theth 13 4-20 ma input or lamphead power and the current drops below 0-10 Vac about 3 ma, the lamphead power becomes the (ground) SETPOINT power. If remote variable power is not required, leave these terminals disconnected. Reversing the ground and signal wires can cause erratic system operation.

Part 775160B E 2003 Nordson Corporation Installation 3-7

Remote Power Level Control The 4-20 ma power level control can be modified to a 0-10 volt power level control if required. Contact your Nordson UV curing representative for more information on this conversion.

Lamp Start-Up Timing Diagram for Remote Input Contact Closures The Off/Reset contact must be closed for the unit to go to Standby or On. Once the lamphead is put into the Standby or On mode the lamphead will remain in that mode until the Off/Reset contact is opened.

OFF/RESET 1

0

STANDBY 1 >100 ms pulse

0 10 seconds to warm up

LAMP ON 1 >100 ms pulse

0 8 seconds to stabilize

Lamp Off Lamp to Standby Lamp to ON Lamp Off 1500003A Figure 3-5 Lamp Start Up Timing Diagram for Remote Input Contact Closures Rapid Startup Standard Startup Use if your system will sit idle in the Standby mode Use to go directly through the warm-up to the On before moving to the On mode. mode. 1. On the LAMP selector of the host machine (or 1. On the LAMP selector of the host machine (or master control unit’s lamp selector), press the master control unit’s LAMP selector), press the Standby button. There will be an approximate LAMP On button. 10 second warm-up time for the magnetron filament. 2. During the next 10 seconds the unit will go through the warm up cycle before turning to On. 2. After the 10 seconds the system will go into standby and remain there indefintely. 3. After approximately 8 more seconds the unit has stabilized and the system is ready to run. NOTE: Do not leave the power supply in the The system ready output contact (TB1) will standby mode for longer than 30 minutes. close. Prolonged standby periods will shorten the magnetron life. 3. Press the On button to enable the UV light. The light will turn on instantly but will take approximately 8 seconds to stabilize. After the 8 seconds, the system ready output contact (TB1) will close.

E 2003 Nordson Corporation Part 775160B 3-8 Installation

Output Connector TB1 All outputs from the TB1 output connector (4) are isolated normally open relay contacts and are rated Refer to Table 3-5 and see Figure 3-4. at 240 Vac, one amp maximum.

Table 3-5 Output Connector TB1 Pin Assignments Pin Function Description 1, 2 High Voltage ON Contact closes when high voltage is applied to the magnetrons. 3, 4 Lamp ON Contact closes when the light has detected light output from the lamphead (after 10-15 seconds). 5, 6 System Ready Contact closes after the power supply unit has been turned on and the light detector light output. In a networked system all power supply units have to be turned on and all lamphead detectors output. 7, 8 Remote Blower This output contact closes when the lamphead is placed in Standby or On. Please note the contact is only rated for one amp @ 240 Vac. 9, 10 Fault Output Contact closes whenever there is a fault present on the system. 11, 12 Not Used

Cable Connections

See Figure 3-4.

Lamphead Refer to Table 3-6.

Table 3-6 Lamphead Cable Connections Cable From To Length (ft) Part Low Voltageg Power supplypp y unit Low-voltageg 25 775027 connector P2P lhdlamphead 50 775036 (Low-voltage(Low-voltage lamphead)lamphead) 75 775037 100 775038 Highgg Voltage Power supplypp y unit High-voltagegg 25 775024 connector P3P lhdlamphead 50 775032 (High-voltage(High-voltage lamphead)lamphead) 75 775033 100 775034

RF Detector NOTE: Each network requires at least one RF detector. If there are multiple light shielding Refer to Table 3-7 chambers at least one RF detector must be located in each chamber. Table 3-7 RF Detector Connections Cable From To Length (ft) Part RF Detector CoolWave powerp RF detector 25 775029 supplyl 50 775050 75 775051 100 775052

Part 775160B E 2003 Nordson Corporation Installation 3-9

The following information identifies the standard Main Control Board switch configurations for the power supply unit. Standard Configurations The systems may be configured to run as standalone or interconnected to form a complete networked system of up to 16 lamps. See Figures 3 -6 and 3-7. NOTE: The main control board was changed in 2003. Figure 3-7 illustrates the previous control board.

1 2 LOC LKOUT/NORMAL 4 REM ANALG EN/DIS FAULT ALL/UNIT SLAVE/MASTER NONE/RE DET LAMP 6“/10” LAMP

OPEN

2 3 1500063B

Figure 3-6 Main Control Board 1. Main control board 3. Power supply address switch 4. 4-2 ma/0-10 Vdc Jumper 2. Dip switches

1 FAULT UNIT/ALL MASTER/SLAVE RF DET/NONE

2 LOCAL LOCK

1 7

3 9

4 10

6 12

0

U6

1008451D NORDSON

OPEN

2 3 1500005A Figure 3-7 Main Control Board Manufactured before 2003 1. Main control board 2. Dip switches 3. Power supply address switch

E 2003 Nordson Corporation Part 775160B 3-10 Installation

Main Control Board Dip Switches LOC LKOUT/NORMAL REM ANALG EN/DIS FAULT ALL/UNIT (REMOTE) There are four or six switches on the main board SLAVE/MASTER NONE/RE DET

DIP switch that need to be set depending upon the 6“/10“ LAMP system configuration. Table 3-8 provides an explanation of each switch.

NOTE: Switches 5 and 6 were added to control boards manufactured after 2002.

OPEN 1500031A Figure 3-8 Dip Switch Configurations

Table 3-8 Main Board Dip Switches Dip Description Function Switch 1 Open/Off = Master unit Configures the power supply to be operated as Closed/On = Remote unit either a master or remote unit. Systems that operate as standalone units are set up as masters. Systems that operate as remote units are configured as remote (slave) units and are networked to be controlled by a master unit. The networked master unit can be contolled locally or by a remote source (such as a PLC, remote operator panel, parent machine, etc.). 2 Open/Off = RF Detector is used Configures the power supply unit to be operated Closed/On = RF Detector is not used with or without an RF detector. Standalone systems or master units cannot operate without an RF detector. An RF detector can be installed at each power supply when necessary. Networked systems are typically configured for the master unit to have one RF detector while its remote units (up to 16 units) do not. NOTE: Up to 16 units can be networked and operate with one RF detector but it is recommended that every six units have one RF detector. 3 Open/Off = Fault individual unit Configures the power supply (standalone or Closed/On = Fault all units networked system) to shut down the individual lamp or the entire network in the event of a fault. 4 Open/On = Enables the front panel Configures the front panel of an individual power controls supply to be enabled or disabled. When disabled, Closed/Off = Disables the front panel all operational functions must be controlled by the controls inputs or the network master. 5 Open/Off = Remote power input On Configures the remote adjustable power input to on Closed/On = Remote power input Off or off. 6 Open/Off = Six-inch power supply is Configures the main control board for the six-inch used/10-inch power supply is not used or the 10-inch power supply and lamphead. Closed/On = Six-inch power supply is not used/10-inch power supply is used

Part 775160B E 2003 Nordson Corporation Installation 3-11

Dip Switch Configurations OPEN = Off Refer to Tables 3-9 through 3-12 for possible CLOSED = On configurations in which the dip switches can be set. NOTE: Switches 5 and 6 were added to control boards manufactured after 2002.

Table 3-9 Single System Operating Locally Power SW1-1 SW1-2 SW1-3 SW-4 SW-5 SW1-6 Supply Standalone Master RF Detector Fault Front Panel Remote 6 in. = (Set Front (Open) (Open) (Open) (Open) Current/ Open/Off Panel to: Voltage Input 10 in. = Local) (Open/Off = Closed/On Enabled) (Closed/On = Disabled)

Table 3-10 Single System Operating Remotely Power SW1-1 SW1-2 SW1-3 SW1-4 SW-5 SW1-6 Supply Standalone Master RF Detector Fault Front Panel Remote 6 in. = (Set Front (Open) (Open) (Open) (Open = Current/ Open/Off Panel to: Enabled) Voltage Input 10 in. = Remote) (Closed = (Open/Off = Closed/On Disabled) Enabled) (Closed/On = Disabled)

Table 3-11 Networked System Operating Locally Power SW1-1 SW1-2 SW1-3 SW1-4 SW-5 SW-6 Supply Master Master RF Detector Fault Front Panel Remote 6 in. = (Set Front (Open) (Open) (Single = (Open = Current/ Open/Off Panel to: Open/Off) Enabled) Voltage Input 10 in. = Local) (All = (Open/Off = Closed/On Closed/On) Enabled) (Closed/On = Disabled) Remote Remote RF Detector Fault Front Panel Remote 6 in. = (Set Front (Closed) (Open=Off) (Single = (Open = Current/ Open/Off Panel to: (Closed=On) Open/Off) Enabled) Voltage Input 10 in. = Remote) (All = (Open/Off = Closed/On Closed/On) Enabled) (Closed/On = Disabled)

E 2003 Nordson Corporation Part 775160B 3-12 Installation

Dip Switch Configurations (contd) Table 3-12 Networked System Operating Remotely Power SW1-1 SW1-2 SW1-3 SW1-4 SW-5 SW-6 Supply Master Master RF Detector Fault Front Panel Remote 6 in. = (Set Front (Open) (Open) (Single = (Open = Current/ Open/Off Panel to: Open/Off) Enabled) Voltage Input 10 in. = Remote) (All = (Closed = (Open/Off = Closed/On Closed/On) Disabled) Enabled) (Closed/On = Disabled) Remote Remote RF Detector Fault Front Panel Remote 6 in. = (Set Front (Closed) (Open=Off) (Single = (Open = Current/ Open/Off Panel to: (Closed=On) Open/Off) Enabled) Voltage Input 10 in. = Remote) (All = Closed = (Open/Off = Closed/On Closed/On) Disabled) Enabled) (Closed/On = Disabled) Power Supply Address Switch See Figure 3-9

The rotary address switch is located on the main board right next to the DIP switch and has 0 through 9 and A through F as locations.

Standalone Units Networked Units

When operating the power supply as a standalone When operating the power supplies in a networked unit (single) the switch can be in any location. To configuration (master/remote), you must set the avoid an unnecessary problems, it is recommended rotary power supply address switches as follows: that it be set to 0. Unit Rotary Switch Setting Master 0 Remote(s) any different value Example: Set the master to 0, remote 1 to 1, remote 2 to 2, etc. 0

1500037A Figure 3-9 Power Supply Address Switch on Main Control Board

Part 775160B E 2003 Nordson Corporation Operation 4-1

Section 4 Operation

WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation.

Introduction

Startup procedures will vary depending on how the system was integrated into other equipment. As a result, the startup procedures documented in this manual are strictly for the UV equipment

Display and Controls

See Figure 4-1 and refer to Table 4-1.

3 5 1

7 Standby 2

4 6 1500006A Figure 4-1 CoolWave System Displays and Controls

E 2003 Nordson Corporation Part 775160B 4-2 Operation

Display and Controls (contd)

Table 4-1 Displays and Controls Item Control Description 1 Main Power Switch Turns the main power on and off to the CoolWave system. 2 POWER SETTING The system is factory set to operate at 100% output. To check the power level, press the Set/Save button. Change the output in 5% increments by pressing the up or down arrow buttons. Changes take place immediately at the time of pressing the up or down arrow button. Press the Set/Save button in order to save these changes. If the Set/Save button is not pressed the power will revert back to the last saved level when the main power is cycled. 3 POWER LEVEL/Display Displays the percentage power output as controlled remotely Output and of the actual power level set on the unit. 4 DISPLAY CURRENT Displays the current flowing to a magnetron. Press the button next to the appropriate magnetron to display that magnetron’s current. To leave this display press the same button again. 5 LAMP Off: Turns the lamphead off. Standby: Applies warm-up power to the magnetron filament and the message WARMUP appears in the display while warming up. Once it is warm, STDBY appears. On: Turns the lamphead on after magnetron filament is warm and LMPDLY is displayed and then LAMPON. 6 NETWORK Sets system operation from the Local or front panel mode to a Remote or external device or controller. 7 Digital Display Displays power levels, operation and fault messages.

Display Messages

During operation, the system displays messages that indicate the system operating status. Table 4-2 lists the display messages. Table 4-2 Display Messages Message Description OFF The power is turned on to the power supply. The lamphead is in the Off mode. WARMUP The magnetron filament is energized. This message will be present for only the filament warm-up time period, which is about 10 seconds. STDBY The filament is warm and the unit is waiting for an On command. LMPDLY Lamp ON has been enabled. The power contactor is closed, and high voltage has been applied to the magnetrons. This message is present only for the lamphead warm-up period, which is about eight seconds. LAMPON Lamp is On at the set power level. L COOL Lamp was On and a Standby command has been received. The magnetron power is shut off and the contactor is open. This message is present only for the cool down period, which is about 30 seconds. The lamphead then goes to a standby state. The unit will not restart until the delay time expires. C DELAY An Off command was received. The lamphead power is turned off. The message is present only for the cool down period, which is about 60 seconds. The unit will not restart until delay time expires.

Part 775160B E 2003 Nordson Corporation Operation 4-3

Fault Messages

When a fault is detected, the unit shuts down the high voltage, turns on the FAULT relay output, and displays a fault message. Table 4-3 lists the fault messages.

Table 4-3 Fault Messages Message Fault Description F PRSW Pressure Switch Insufficient or no air pressure in the lamphead. F LOCK Interlock External interlock input is open. F OTMP Over Temperature Transformer thermal switch(es) open. May be caused by insufficient air flow through power supply cabinet. F STOP STOP STOP interlock input is open. F CABL Cable Interlock The high-voltage cable and/or the low-voltage cable from the Open power supply to the lamphead is disconnected or open. F RF RF Interlock RF detector is disconnected or has sensed high levels of RF from the lamphead. F POWR Power Light output or magnetron current has been sensed when the power supply is in the Off mode. F LOUT Lamp Out There was insufficient output from the light detector when the power supply energized the magnetrons in the Lamp On mode. F NETW Network The control board can no longer communicate with a previously detected system. F IBAL Magnetron The magnetrons are turned on (LAMPON) and the magnetron Current Imbalance currents differ by more than 100 ma for a period exceeding about 600 ms. F OVER Magnetron Over Either magnetron current exceeds 950 ma in the LAMPON Current mode.

Resetting a Fault Operating in the Local Mode: Press the Off button to clear a fault once it has been corrected.

Operating in the Remote Mode: Open and close the off/reset contact to reset a fault once it has been corrected.

NOTE: Once the fault has been corrected a remote unit can be reset by either the front panel of the master unit or a host controlling the master unit.

E 2003 Nordson Corporation Part 775160B 4-4 Operation

Lamp Start-Up Timing Diagram for Remote Input Contact Closures

The Off/Reset contact must be closed for the unit to go to Standby or On. Once the lamphead is put into the Standby or On mode the lamphead will remain in that mode until the Off/Reset contact is opened.

NOTE: If the LAMP On message does not appear, refer to the Troubleshooting section.

OFF/RESET 1

0

STANDBY 1 >100 ms pulse

0 10 seconds to warm up

LAMP ON 1 >100 ms pulse

0 8 seconds to stabilize

Lamp Off Lamp to Standby Lamp to ON Lamp Off 1500003A Figure 4-2 Lamp Start Up Timing Diagram for Remote Input Contact Closures

Part 775160B E 2003 Nordson Corporation Operation 4-5

Startup

NOTE: Refer to the Troubleshooting section if the system faults during startup.

Locally Operated Units Table 4-4 Startup Procedures for Locally Operated Units Step Single Unit Multiple Units Networked to a Master Unit Operated Locally Operated Locally 1 Switch the electrical disconnect enclosure to ON. 2 Turn the main power switch on the front of the power supply unit to the on position. The power on message begins to scroll. The power on message begins with the words UV CURING. Three numbers will then scroll listing the software versions for the display board, main control board, and the phase board respectively. 3 Make sure that all interlocked access doors are closed and that the exhaust fan is running if not directly connected to the power supply blower contacts. If external interlocks are wired and open, a fault message F LOCK will appear in the display. 4 On the NETWORK selector, press Local. Set the NETWORK configuration. S On the master unit’s NETWORK selector, press Local. S On the remote units’ NETWORK Selector, press Remote. Continued...

E 2003 Nordson Corporation Part 775160B 4-6 Operation

Locally Operated Units (contd) Step Single Unit Multiple Units Networked to a Master Unit Operated Locally Operated Locally 5 Set the POWER SETTING. Set the POWER SETTING. 1. Press the Set/Save button on the 1. On the master unit, press the Set/Save POWER SETTING selector until the button on the POWER SETTING selector power level is displayed. until the power level is displayed. 2. Press the up or down arrows to set the 2. Press the up or down arrows to set the desired power level. desired power level. 3. Press the Set/Save button to save the 3. Press the Set/Save button to save the setting. setting. 4. Set the POWER SETTING at each remote unit between 25 and 100 using the same procedure as the master unit. The POWER SETTING at each remote unit will determine the power output percentage for that unit. For example, if your master unit’s POWER SETTING is 100 and your first remote unit’s POWER SETTING is set at 50, that remote unit will run on 50% output. If the second remote unit’s POWER SETTING is set at 75 then that unit will run at 75% output. Each remote POWER SETTING can be different. Each setting is determined by the POWER SETTING entered in the master control unit and is proportional to the maximum set at each power supply. 6 Enable the cooling fan by either an external/remote switch or a set of contacts from the power supply. If the exhaust fan is wired to the normally open set of contacts on the power supply they will close when the lamphead is put in STDBY or LAMPON mode. If there is insufficient pressure (less than 7 in. H2O static pressure) there will be a system fault and the message F PRSW will appear in the display. (Check for proper pressure with the appropriate instrumentation.) Continued...

Part 775160B E 2003 Nordson Corporation Operation 4-7

Step Single Unit Multiple Units Networked to a Master Unit Operated Locally Operated Locally 7 Start up the lampheads. NOTE: If the LAMPON message does not appear, refer to the Troubleshooting section. Rapid Startup Use this procedure if your system will sit in an idle state in the STDBY mode before moving to the On mode. 1. On the LAMP selector (or master control unit’s LAMP selector) press the LAMP Standby button. There will be an approximate 10 second warm-up time for the filament transformer. WARMUP will appear on the display. 2. After approximately 10 seconds the system will display STDBY until Lamp On is pressed. 3. Press the LAMP On button. It will take approximately eight seconds to stabilize. Or Standard Startup Use this procedure to go directly through the warm-up to the On mode. 1. On the LAMP selector (or master control unit’s LAMP selector) press LAMP On. WARMUP will appear on the display. 2. After approximately 10 seconds the unit will display LMPDLY. It will take 10 seconds to stabilize as it goes thru the warm up cycle before turning to On. 3. After approximately 10 more seconds and the unit(s) has stabilized at the set power level, LAMPON will appear in the display and the system is ready to run.

E 2003 Nordson Corporation Part 775160B 4-8 Operation

Remotely Operated Units NOTE: The system can be wired to initiate lamphead start from either the process machine or Refer to Table 4-5. from the UV power supply control panel.

Table 4-5 Startup Procedures for Remotely Operated Units Step Single Unit and Units Networked to a Master Unit Operated Remotely 1 Switch the electrical disconnect enclosure to ON. 2 Turn the main power switch on the front of the power supply unit to the on position. The power on message begins to scroll. The power on message begins with the words UV CURING. Three numbers will then scroll listing the software versions for the display board, main control board, and the phase board respectively. 3 Make sure that all interlocked access doors are closed and that the exhaust fan is running. If external interlocks are wired and open, a fault message F LOCK will appear in the display. 4 On the NETWORK selector, press Remote. NOTE: For networked units, press Remote at each NETWORK selector. 5 Set the POWER SETTING. There are two ways of setting the POWER SETTING. If the power level will be set at the control panel prior to turning on and off remotely (Remote Operation), select the desired power level and save it while the unit is in Local mode. At the Network Selector then select Remote. 6 Enable the cooling fan by either an external/remote switch or a set of contacts from the power supply. If the exhaust fan is wired to the normally open set of contacts on the power supply they will close when the lamphead is put in STDBY or LAMPON mode. If there is insufficient pressure (less than than 7 in. H2O static pressure) there will be a system fault and the message F PRSW will appear in the display. (Check for proper pressure with the appropriate instrumentation.) 7 There are many ways that the system can be configured to operate Remotely. By utilizing the power supply I/O the UV system can be controlled from a simple panel or fully automated to work in concert with a complete process. Contact a Nordson UV Curing representative for details.

Part 775160B E 2003 Nordson Corporation Operation 4-9

Shutdown S Cooling air for the lamphead ceases or reaches an insufficient level The system will stop if any of the following S Any of the safety interlocks wired into the UV conditions occur: equipment are interrupted. These include exhaust fan, access panels, doors and process S LAMP STOP push button on UV operator equipment station is pressed S Any fault condition occurs S The power supply switch is turned to the off position Refer to Table 4-6 for shutdown procedures for the CoolWave UV system. S The LAMP On/Off switch is turned to Off

Table 4-6 Shutdown Procedures Step Shutting Down Systems Locally Shutting Down Systems Remotely 1 Press the Lamp Off button. Press the Lamp Off button on the remote or host machine. 2 Allow the lampheads five minutes of cool Allow the lampheads five minutes of cool down before shutting off the cooling air. down before shutting off the cooling air. CAUTION: Failure to do this can cause CAUTION: Failure to do this can cause problems restarting the lamps as well as problems restarting the lamps as well as greatly reduce the life of the lamphead greatly reduce the life of the lamphead bulbs. bulbs. Failure to do this can cause problems Failure to do this can cause problems restarting the lamps as well as greatly restarting the lamps as well as greatly reduce the life of the lamphead bulbs. reduce the life of the lamphead bulbs. NOTE: Typically the cooling fan will be controlled by the remote or host machine through the I/O of the UV System.

3 Turn off the main power to all units.

E 2003 Nordson Corporation Part 775160B 4-10 Operation

Part 775160B E 2003 Nordson Corporation Maintenance and Repair 5-1

Section 5 Maintenance and Repair

WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation.

Establish acceptable curing levels for your process Maintenance and and then develop a maintenance schedule that fits Replacement Schedule your needs. Radiometers can be used to measure relative readings for spectral output as a means of Table 5-1 lists typical maintenance guidelines and monitoring spectral intensity. replacement schedules for the components of the CoolWave UV microwave applied curing system The maintenance and replacement schedule for with ten-inch lamphead. the system will depend upon your: S Recommended maintenance to the lamphead application process consists of changing bulbs and reflectors and S plant environment cleaning or replacing filter material. It is also S recommended that reflectors be cleaned quality of cooling air passing through the periodically. system S coating formulation Recommended maintenance to the power supply consists of cleaning or changing the cooling fan filter material and removing dust from the power supply.

E 2003 Nordson Corporation Part 775160B 5-2 Maintenance and Repair

Maintenance and Replacement Schedule (contd) Table 5-1 Typical Maintenance and Replacement Schedule Component Maintenance Guidelines Replace component... UV Bulb Bulbs are warranted for a specific number of hours when operating after 3000 under manufacturermanufacturer’s s operationoperation specificationsspecifications (hours(hours varyvary with hours of differing bulbs). Depending on your application, some installations operation mamayy provideprovide acceptableacceptable curingcuring well beyondbeyond the warrantywarranty. or as needed NOTE: Do not touch or handle the bulb with bare hands. Be sure to cleanl themth with ith a lint-freeli t f cloth l th or tissueti tot remove any fingerprintsfi i t that might be present. Magnetrons The magnetrons are warranted for a specific number of hours when after 3000 operating under the manufacturer’s operation specifications. Each hours of application will be different and, in many cases, the magnetron life operation will last well beyond the warranty. or as needed Screen The screen should be free of all debris such as cured material, lint, as needed dust or anything that might impede cooling or UV transmittance. Soaking in a compatible to remove any such items may clean the screen. Do not use damaged screens. This can result in RF detec- tor leakage.

Reflectors Reflector surfaces should be cleaned every 500 working hours as needed (more frequently in dirty environments) and at every bulb change. Wipe the reflector surface and the cavity with a clean, lint-free cloth dipped in a suitable solvent such as isopropyl alcohol. Be careful when replacing reflectors. They are made of glass and may break if dropped or forced. Never use metal polish or any abrasive media to clean the reflectors.

Pressure Switch Pressure switches are rated for operation between -40 _C and when failure 120 _C. If your system experiences repeated loss of cooling air, the occurs pressure switch may overheat and fail. Make sure that the lamphead cooling fan cools the system sufficiently to avoid pressure switch and other internal lamphead component failures. Filters Filter material is designed to capture dust and contaminants from the plantplant before enteringentering the UV equipmentequipment.. These filters are Remote blower located on the lampheads, remote blowers, and some power Weekly suppliessupp es (customer-supplied (custo e supp ed filters). te s) Eventually, e tua y, the t e filters te s will or as needed cooling fan become loaded with matter and will start to impede the flow of air. electrical A dirty filter also will release matter into the air stream that may enclosure/ deposit on the part being cured as well as the bulb and reflector. lamphead Use soap and to wash all filter material that provides cooling to any part of your UV system.

Part 775160B E 2003 Nordson Corporation Maintenance and Repair 5-3

Replacement Procedures

Preparation 1. Turn off the UV system from the process equipment controller or at the UV panel. 2. Allow the lamphead fan to complete its cooling cycle. If this has been prevented by premature isolation of the control cabinet, always allow sufficient time for the bulb to cool before proceeding. 3. Turn off the main electrical disconnect. Follow all relevant OSHA established lockout procedures. 4. If the lamphead has a and metal connector, disconnect the interconnect cables. 5. If necessary, loosen the M6 lamphead mounting fasteners and remove the assembly from the brackets.

Bulb Replacement 1. Perform the Preparation procedure in this section. 2. See Figure 5-1. Turn or place the lamphead assembly so that the entire bulb area is exposed and accessible. 3. Remove the eight screws from the lamphead base to remove the RF screen.

1500013A Figure 5-1 RF Screen Removal

E 2003 Nordson Corporation Part 775160B 5-4 Maintenance and Repair

Bulb Replacement (contd) NOTE: Do not touch the quartz portion of the bulb with bare hands. Use protective gloves. 4. See Figure 5-2. Grasp the ends of the bulb and push it to one side. Lift one end of the bulb out of the retaining hole; the other end of the bulb should come out of the other retaining hole. 5. Place one end of the new bulb into the retaining hole, push to one side and lower the bulb into place. Install the remaining end of the bulb into the other retaining hole.

6. Place the old bulb in the new bulb packaging 1500014A and dispose of according to your company’s Figure 5-2 Bulb Replacement disposal policies. Refer to page 1-5 in the Safety section for the bulb return policy. 7. Install the RF screen to the lamphead base with the eight screws.

Reflector Replacement Two types of reflectors may be used in the lamphead: Flood and Focus. The reflectors use different retaining brackets within the lamphead. Remove the Reflectors 1. Perform the Preparation procedure on page 5-3. 2. Turn or place the cradle assembly so that the entire bulb area is exposed and accessible. 3. Remove the eight screws from the lamphead base to remove the RF screen. 1500015A NOTE: Do not touch the quartz portion of the bulb Figure 5-3 Retaining Bars Removal with bare hands. Use protective gloves. 4. Remove the bulb. Refer to Bulb Replacement beginning on page 5-3. 5. See Figure 5-3. Remove the six M3 mounting screws and the two retaining bars from the lamphead base.

Part 775160B E 2003 Nordson Corporation Maintenance and Repair 5-5

6. See Figure 5-4. Carefully slide the two reflectors from the lamphead base.

NOTE: Great care should be taken when replacing reflectors as they are made of glass and may break if dropped or forced.

1500016A Figure 5-4 Reflector Replacement

Install the Reflectors 1. Slide the reflectors into the lamphead base. NOTE: The inside edge of the reflector should slide into the notches of the retainers.

2. Set the retaining brackets in place. The placement of the retaining brackets differs between focus and flood reflectors.

Focus Reflectors: See Figures 5-5 and 5-6. The lip on the focus bracket will go to the inside The edge of the reflector will sit on the retainer of the lamphead and wrap around the reflector. springs on the inside edge of the bracket. Line up the retaining bracket mounting holes with the mounting holes in the lamphead base.

1500089A 1500091A Figure 5-5 Focus Reflector Curve and Retaining Figure 5-6 Placing the Focus Retaining Bracket Bracket

E 2003 Nordson Corporation Part 775160B 5-6 Maintenance and Repair

Install the Reflectors (contd) The lip on the flood bracket will go to the inside of the lamphead and wrap around the edge of Flood Reflectors: See Figures 5-7 and 5-8. the reflector. The curve of the reflector causes The edge of the reflector will sit on the retainer the reflector to sit farther away from the side of springs on the inside edge of the bracket. the lamphead. Line up the retaining bracket mounting holes with the mounting holes in the lamphead base.

1500094A 1500099A Figure 5-7 Flood Reflector Curve and Retaining Figure 5-8 Placing the Flood Retaining Bracket Bracket

3. Install the six M3 mounting screws to secure the reflectors and retaining brackets. 4. Install the bulb. 5. Install the RF screen to the lamphead base.

Internal Component Replacement Remove the lamphead cover to replace the following internal components:

S Pressure switch S Light detector board S Starter bulb S Magnetron NOTE: Steps 2 through 4 are optional and are taken only to prevent any damage to the RF screen or bulb. 1. Perform the Preparation procedure on page 5-3. 2. Turn or place the lamphead assembly so that the entire bulb area is exposed and accessible.

Part 775160B E 2003 Nordson Corporation Maintenance and Repair 5-7

3. Remove eight screws from the lamphead base to remove the RF screen.

NOTE: Do not touch the touch the quartz portion of the bulb with bare hands, use protective gloves. 4. Remove the bulb. Refer to Bulb Replacement on page 5-3. 5. See Figures 5-9 and 5-10. Remove the 12 screws from the lamphead cover to remove the cover.

1500017A Figure 5-9 Lamphead Cover Removal (Top Four Screws)

1500098A Figure 5-10 Lamphead Cover Removal (Eight screws -four on each side)

NOTE: Step six can be skipped if you are only replacing the pressure switch. 6. Remove the transformer and connector bracket by removing the three screws identified in Figure 5-11.

1500078A Figure 5-11 Transformer and Connector Bracket Removal

E 2003 Nordson Corporation Part 775160B 5-8 Maintenance and Repair

Internal Component Replacement (contd) 7. See Figure 5-12. Pull the the transformer and connector bracket from the lamphead base

1500079A Figure 5-12 Transformer and Connector Bracket

Pressure Switch 1. Follow steps 1-5 under Internal Component Replacement on page 5-6 to remove the lamphead cover. 2. Note the orientation of the pressure switch with regard to the airflow direction. 3. See Figure 5-13. Remove the M3 screws securing the pressure switch to the insulating plate.

1500018A Figure 5-13 Pressure Switch Removal

4. See Figure 5-14. Disconnect the the two wires and connect them to the new pressure switch in the same orientation. 5. Fasten the pressure switch to the insulator plate and stainless steel mounting bracket with the M3 fasteners. 6. Assemble the lamphead.

1500019A Figure 5-14 Pressure Switch Wires

Part 775160B E 2003 Nordson Corporation Maintenance and Repair 5-9

Light Detector Board 1. Follow steps 1-7 under Internal Component Replacement beginning on page 5-6 to remove the lamphead cover. 2. See Figure 5-15. Disconnect the light detector board. 3. Remove the two M4 screws. 4. Replace and connect the new board and install it with the M4 screws. 5. Install the transformer and connector bracket.

6. Install the cover on the lamphead base. 1500082A 7. Install the bulb and RF screen, if necessary. Figure 5-15 Light Detector Board Replacement

Starter Bulb 1. Follow steps 1-7 under Internal Component Replacement beginning on page 5-6 to remove the lamphead cover. 2. See Figure 5-16. Cut or remove the threadlocking material from the base of the bulb to remove the bulb. 3. Apply a small dot of threadlocking material to the base of the new bulb and install it. 4. Install the transformer and connector bracket. 5. Install the cover on the lamphead base. 1500083A 6. Install the bulb and RF screen, if necessary. Figure 5-16 Starter Bulb Replacement

E 2003 Nordson Corporation Part 775160B 5-10 Maintenance and Repair

Magnetron NOTE: Each lamphead contains two magnetrons. The replacement procedure is the same for each magnetron.

Remove the Magnetron 1. Follow steps 1-7 under Internal Component Replacement beginning on page 5-6 to remove the lamphead cover. NOTE: Be careful not to cut or damage the sleeving.

2. See Figure 5-17. Cut the four ties securing the 1500084A black sleeving over the high-voltage ring terminals. Figure 5-17 Black Sleeving

3. See Figure 5-18. Slide the sleeving down to expose the two ring terminals. Remove the two screws.

1500066A Figure 5-18 Ring Terminals

4. See Figure 5-19. Remove the four screws, washers and nuts that secure the magnetron to the lamphead base. Remove the magnetron.

1500085A Figure 5-19 Remove the Magnetron

Part 775160B E 2003 Nordson Corporation Maintenance and Repair 5-11

Install the Magnetron 1. See Figure 5-20. Inspect the gasket around the antenna of the new magnetron, making sure it is smooth and free of debris. Check for signs of arcing or burning around the flange. If arcing or burn marks are present, contact your Nordson representative. 2. Carefully insert the antenna through the hole in the lamphead base.

1500086A Figure 5-20 Install the Magnetron

3. Make sure the magnetron gasket is sealed evenly on the flange and secure the magnetron to the lamphead with the four screws, washers, and nuts. Tighten the nuts to 1.9 NSm (17-in. lb). 4. Secure the two high-voltage ring terminal on each magnetron with the two screws. 5. Pull the black sleeving up over the high-voltage terminal and secure it in place with tie wraps. 6. Install the transformer and connector bracket. 7. Install the cover on the lamphead base. 8. Install the bulb and RF screen, if necessary.

E 2003 Nordson Corporation Part 775160B 5-12 Maintenance and Repair

Fuse Replacement See Figure 5-21 to identify the three fuses on the main control board that are replaceable.

Fuse

Fuse Fuse

1500073A Figure 5-21 Main Control Board Fuses

Air Filter Cleaning and Supply Cooling Fan NOTE: Repeat the same procedure for all external blowers.

NOTE: Some filter media can be washed and reused. Refer to the users’ manual for your blower. 1. Turn off the main electrical disconnect. Follow all relevant OSHA-established lockout procedures. 2. Locate the cooling fan on the power supply. It is located on the front side of the power supply. 3. Make sure the safety cover is clean and free of any debris. 4. Examine fan blades for contamination. Clean or replace if necessary.

Part 775160B E 2003 Nordson Corporation Troubleshooting 6-1

Section 6 Troubleshooting

WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation.

Introduction

This section contains troubleshooting procedures. These procedures cover only the most common problems that you may encounter. If you cannot solve the problem with the information given here, contact your local Nordson representative for help.

General Troubleshooting NOTE: If your unit does not start up, disconnect power to the unit then remove the cover and check the fuses. See Figure 7-2 for fuse locations.

Problem Possible Cause Corrective Action 1. Lamp Fault The light detector outputs a Check the magnetron current, main voltage when the lamphead is in fuses, phase control board, and light Fault Message: operation: the voltage drops detector. F LOUT below a minimum Interconnect cable at lamphead or Disconnect and reconnect the cable. power supply is loose Bulb has failed Replace the bulb. 2. Pressure Fault Cooling fan is not running Remote Blower: Check the motor starter, fuses, and overloads. Reset Fault Message: or replace overloads and/or fuses if F PRSW necessary. Cooling fan is running in reverse Check the wires at the blower and at the starter, check the fan rotation. Filter on cooling fan is dirty Replace the filter on the blower. Wash the filter on the remote blower with soap and water. Continued...

E 2003 Nordson Corporation Part 775160B 6-2 Troubleshooting

General Troubleshooting (contd)

Problem Possible Cause Corrective Action 2. Pressure Fault Remote cooling fan is wired Switch two of the main input power improperly wires on the three-phase remote Fault Message: blower. Air flow will be in the same F PRSW (contd) direction for all combinations; however, there will be greater air flow when the motor is spinning the correct direction. Follow the motor rotation diagram on the motor. Pressure sensor has failed The pressure sensor is a normally open switch that closes with 7-in. wc static pressure. Make sure both the external and internal port of the switch are open and there are no obstructions. If there are no obstructions and the blower is operating correctly, replace the switch. Pressure drop in remote blower Ducting to the remote blower should ducting is too great be large enough with minimum of sharp bends to supply adequate ventilation. If pressure faults have consistently been a problem, you may want to consider mounting the remote blower closer to the lamphead or increasing the duct size or blower. 3. Magnetron Current The current in one or both Reset the lamphead and restart the Fault magnetrons has dropped below system. If the problem still exists 200 ma for a duration of more than there may be a magnetron failure. Fault Message: 600 ms F POWR Magnetron current is detected Reset the lamphead and restart the when unit is off system. If the problem still exists there may be a magnetron failure. 4. Interlock Fault Open external interlock Check all system interlocks.

Fault Message: F LOCK

5. Power Supply Insufficient air flow to the power Clean the blower filters and make Overtemp supply sure that there are no obstructions in the blowers and the filters. Fault Message: F OTMP Main power supply Check the main power supply for proper voltage.

Continued...

Part 775160B E 2003 Nordson Corporation Troubleshooting 6-3

Problem Possible Cause Corrective Action 6. Magnetron Magnetron current has exceeded Check all the power supply to Overcurrent Fault 950 ma lamphead cables for damage or arcing. Check for signs of arcing in Fault Message: the lamphead. F OVER

7. Network Fault A fault has been detected Determine the unit with the fault and somewhere on the network; the correct the fault. Clear the master or Fault Message: master shows F NETW and the individual control unit. F NETW problem unit will display the specific fault

8. E-Stop system will Pins 1 and 2 on the input are not Add an E-Stop jumper between pins not start jumpered 1 and 2.

Fault Message: F STOP E-Stop buttons are activated either Check and release all E-Stops. on the power supply or external equipment

9. Irradiator will not light Power supply to lamphead cables Check the cable connections. Check disconnected or faulty the continuity of cables. Fault Message: F CABL

10. RF Fault RF detector switch is not set Check the dip switch setting on the properly on control board main control board. Fault Message: F RF RF detector is not properly Check the connections. connected RF cable is faulty Check the continuity of the cable. Replace the cable if necessary. RF detector is detecting a high Check the lamphead screen for holes level of RF and tears. Replace the lamphead screen if necessary. Check to make sure the screen is securely fastened. 11. Magnetron current The current from magnetron 1 and Check the SCRs and phase control imbalance magnetron 2 has differed by more board. Check that the fuses are ok. than 100 ma for a time longer than Fault Message: 600 ms F IBAL Magnetron current has fallen Check the block five ohm below 200 milliamps feedback for short or open. Continued...

E 2003 Nordson Corporation Part 775160B 6-4 Troubleshooting

General Troubleshooting (contd)

Problem Possible Cause Corrective Action 12. Open filament Filament transformer fuse blown Check fuse on main circuit board. transformer circuit

Fault Message: F FUSE Filament transformer bad Check output of filament transformer. Short or open in cable to filament Remove the LV cable from the power transformer supply and check Pin 9 and Pin 10 for continuity. Filament in magnetron failed Replace the magnetron.

Troubleshooting Bulb Problems

NOTE: Any bulb that has been touched or contaminated should be cleaned with alcohol prior to use. Failure to do so can and possibly will result in premature failure of the bulb.

Problem Possible Cause Corrective Action 1. Bulbs have white Quartz was touched when bulb Replace the bulb. The spectral fingerprints on quartz was installed: finger dirt and oils output has diminished. In the future, were deposited on the quartz and do not touch the quartz portion of the burned into the quartz when the bulb under any circumstances. bulb was running 2. New bulb does not Pressure seal has been broken Replace the bulb. start 3. Quartz portion of bulb Bulb is overheating Check the ventilation. Clean the filter is rippled material. Check the pressure switch, it may have failed. 4. Quartz has a white or Bulb is overheating Replace the bulb. If UV output is gray cloudy below acceptable levels. appearance

Troubleshooting Curing Process Problems

Problem Possible Cause Corrective Action 1. System running ok Reflectors are installed in the Check to make sure reflectors are but material not wrong orientation installed and are installed correctly. curing Reflectors are badly damaged or Replace the reflectors. dirty RF screen dirty Remove and clean the RF screen.

Part 775160B E 2003 Nordson Corporation Parts 7-1

Section 7 Parts

Introduction

To order parts, call the Nordson Customer Service Center or your local Nordson representative. Use this five-column parts list, and the accompanying illustration, to describe and locate parts correctly. Using the Illustrated Parts List Numbers in the Item column correspond to numbers that identify parts in illustrations following each parts list. The code NS (not shown) indicates that a listed part is not illustrated. A dash (—) is used when the part number applies to all parts in the illustration.

The number in the Part column is the Nordson Corporation part number. A series of dashes in this column (------) means the part cannot be ordered separately.

The Description column gives the part name, as well as its dimensions and other characteristics when appropriate. Indentions show the relationships between assemblies, subassemblies, and parts.

S If you order the assembly, items 1 and 2 will be included. S If you order item 1, item 2 will be included. S If you order item 2, you will receive item 2 only. The number in the Quantity column is the quantity required per unit, assembly, or subassembly. The code AR (As Required) is used if the part number is a bulk item ordered in quantities or if the quantity per assembly depends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list. Notes contain important information about usage and ordering. Special attention should be given to notes.

Item Part Description Quantity Note — 0000000 Assembly 1 1 000000 S Subassembly 2 A 2 000000 SS Part 1

E 2003 Nordson Corporation Part 775160B 7-2 Parts

Lamphead See Figures 7-1 and 7-3.

Item Part Description Quantity Note 1 775010 FOCUS LAMPHEAD, CoolWave 1 1 775015 FLOOD LAMPHEAD, CoolWave 1 2 775042 S MERCURY BULB, CoolWave, 10 in., H 1 A, B 2 775043 S BULB, CoolWave, 10 in., D 1 A, B 2 775044 S GALIUM BULB, CoolWave, 10 in., V 1 A, B 2 775045 S INDIUM BULB, CoolWave, 10 in. 1 A, B 2 775046 S MERCURY PLUS BULB, CoolWave, 10 in., H+ 1 A, B 3 775060 S BRACKET, retaining reflector, CoolWave, 2 B focused 3 775061 S BRACKET, retaining reflector, CoolWave, flood 2 B 4 775062 S SWITCH, pressure, CoolWave, 10 1 B 5 775064 S FILAMENT TRANSFORMER, CoolWave 2 B 6 775040 S BULB, starter 1 7 775090 S FOCUSED REFLECTOR, CoolWave, standard 2 B, C 7 775092 S FOCUSED REFLECTOR, CoolWave, 3.1 2 B, C 7 775100 S FLOOD REFLECTOR, CoolWave, standard 2 B, C 8 775115 S DEFLECTOR, strip, quartz, CoolWave 1 B 9 775120 S SCREEN, lamphead, CoolWave 1 B 10 775130 S MAGNETRON PAIR, 3.0 Kw, CoolWave 1 B 11 775139 S SENSOR, light, CoolWave, 6/10 1 B 12 ------S SCREW, M4 mounting holes 8 13 ------S PAN HEAD SCREW, M4 x 8, Phillips, steel, 14 plated 14 ------S PAN HEAD SCREW, M4 x 8, Phillips with lock 8 washer, steel, zinc plated 15 ------S BUTTON HEAD SOCKET SCREW, M3 x 10, 4 with Nylok nut 16 ------S BUTTON HEAD SOCKET SCREW, M3 x 5, 8 stainless steel 17 ------S PAN HEAD SCREW, M5 x 8, Phillips, steel, 4 zinc plated 18 ------S SCREW, M5 mounting holes 12 NS 775160 MANUAL, CoolWave 1 B NOTE A: Order the correct bulb for your particular system. B: Recommended spare part. Keep this part in inventory to avoid unplanned downtime. C: Order the correct reflector for your particular system. NS: Not Shown

Part 775160B E 2003 Nordson Corporation Parts 7-3

1 1

3 8

12 12

18 2 14

13 15

13 2

3 7

9 16

17 4 17 4

10

10

5

11

5

6

1500026A Figure 7-1 CoolWave Lamphead

E 2003 Nordson Corporation Part 775160B 7-4 Parts

Power Supply and RF Detector See Figures 7-2 and 7-3. Item Part Description Quantity Note 19 775019 50/60 HZ POWER SUPPLY, CoolWave 1 20 775066 S POWER TRANSFORMER, CoolWave 2 21 775068 S TRANSFORMER, step down, 480-240 1 22 775076 S 50/60 Hz CAPACITOR, 1.1 Mf, 2500 Volt, 4 CoolWave 23 775080 S FUSE, kit, CoolWave 1 A, B 23a ------SS FUSE, 30 amp 3 B 23b ------SS FUSE, 1 amp 2 B 23c ------SS FUSE, 160 microamp, 250 volt 1 B 23d ------SS FUSE, 2 amp, 250 volt 2 B 24 775085 S FAN, cooling, CoolWave 2 A 25 775140 S PCB, CONTROL, CoolWave 1 26 775142 S PCB, DISPLAY, CoolWave 1 27 774144 S PCB, PHASE, CoolWave 1 28 775146 S PCB, I/O, CoolWave 1 29 775150 S MODULE, rectifier, CoolWave 2 30 ------S PAN HEAD SCREW, M5 x 10, with captive lock 10 washer, stainless steel 31 775022 RF DETECTOR, CoolWave, 6/10 1 NOTE A: Recommended spare part. Keep this part in inventory to avoid unplanned downtime. B: The fuse kit part, 775080, contains three 30 amp, 500 volt main fuses; two one amp, 500 volt fuses for the step down transformer; one 160 microamp, 250 volt control board fuse; and two two amp, 250 volt fuse for the filament transformer.

Part 775160B E 2003 Nordson Corporation Parts 7-5

19 25 26 23 25 23d 23c 24

23d 20

29

22 27

21

20 28

31

REAR VIEW

23 29 20 24

23a 23b

24

30 30

30 30 20 22 30 21

SIDE VIEW 1500025B Figure 7-2 CoolWave Power Supply and RF Detector

E 2003 Nordson Corporation Part 775160B 7-6 Parts

CoolWave Cables

See Figure 7-3. Order the correct cable length for your particular system. Item Part Description Quantity Note 32 775024 25 ft HIGH VOLTAGE CABLE, universal 1 32 775032 50 ft HIGH VOLTAGE CABLE, universal 1 32 775033 75 ft HIGH VOLTAGE CABLE, universal 1 32 775034 100 ft HIGH VOLTAGE CABLE, universal 1 33 775027 25 ft LOW VOLTAGE CABLE, universal 1 33 775036 50 ft LOW VOLTAGE CABLE, universal 1 33 775037 75 ft LOW VOLTAGE CABLE, universal 1 33 775038 100 ft LOW VOLTAGE CABLE, universal 1 34 775029 25 ft CABLE, RF detector, 6/10 1 34 775050 50 ft CABLE, RF detector, 6/10 1 34 775051 75 ft CABLE, RF detector, 6/10 1 34 775052 100 ft CABLE, RF detector, 6/10 1 35 775031 NETWORK CABLE, 6 ft, 6/10 1 NS 775162 60 Hz BLOWER, external, 60 Hz 1 NS 775165 50 Hz BLOWER, external, 50 Hz 1 NS: Not Shown

Part 775160B E 2003 Nordson Corporation Parts 7-7

NOTE: Most of the recommended spare parts are Recommended Spare listed with a level number (1, 2, or 3) to identify the Parts part’s level of importance to system operation. Level 1 parts are critical to the day-to-day operation Keep the following parts in inventory to avoid of the UV curing system so be sure to keep these unplanned downtime. Quantities listed support a parts in inventory. lamphead or power supply. Part Description Quantity Level Note 775010 FOCUS LAMPHEAD, CoolWave 1 3 775015 FLOOD LAMPHEAD, CoolWave 1 3 775019 50/60 HZ POWER SUPPLY, CoolWave 1 3 775022 RF DETECTOR, CoolWave, 6/10 1 3 775024 25 ft HIGH VOLTAGE CABLE, universal 1 3 775027 25 ft LOW VOLTAGE CABLE, universal 1 3 775029 25 ft CABLE, RF detector, 6/10 1 3 775031 NETWORK CABLE, 6 ft, 6/10 1 3 775042 MERCURY BULB, CoolWave, 10 in., H 1 1 A 775043 IRON BULB, CoolWave, 10 in., D 1 1 A 775044 GALIUM BULB, CoolWave, 10 in., V 1 1 A 775045 INDIUM BULB, CoolWave, 10 in. 1 1 A 775046 MERCURY PLUS BULB, CoolWave, 10 in., H+ 1 1 A 775040 BULB, starter 1 2 775062 SWITCH, pressure, CoolWave, 10 1 1 775064 FILAMENT TRANSFORMER, CoolWave 2 2 775080 FUSE, kit, CoolWave 1 1 775076 50/60 Hz CAPACITOR, 1.1 Mf, 2500 Volt, 4 3 CoolWave 775140 PCB, CONTROL, CoolWave 1 2 775142 PCB, DISPLAY, CoolWave 1 2 774144 PCB, PHASE, CoolWave 1 2 775146 PCB, I/O, CoolWave 1 2 775085 FAN, cooling, CoolWave 2 3 775090 FOCUSED REFLECTOR, CoolWave, standard 2 3 B 775100 FLOOD REFLECTOR, CoolWave, standard 2 3 B 775115 DEFLECTOR, strip, quartz, CoolWave 1 3 775120 SCREEN, lamphead, CoolWave 1 1 775130 MAGNETRON PAIR, 3.0 Kw, CoolWave 1 1 775136 QUARTZ PLATE, kit, lamphead 1 - 775139 SENSOR, light, CoolWave, 6/10 1 3 775160 MANUAL, CoolWave 1 - NOTE A: Order the correct bulb for your particular system. B: Order the correct reflector for your particular system.

E 2003 Nordson Corporation Part 775160B 7-8 Parts

Part 775160B E 2003 Nordson Corporation Parts 7-9

19 23 1 25 26 25 23d 23c

24 31 32 33 3 23d 8 20 12 1 29 34 12 19

18 14 2 22 27 13 21 15 20 13 28 2 35

31 3 7 19 9 16 1

REAR VIEW 17 4 17 23 29 4 20 24

23a 23b

10

24 10 19 5

1 11 30 30 5

30 6 30 20 22 30 21 SIDE VIEW 1500020B

Figure 7-3 CoolWave Ultraviolet UV Microwave Curing System Parts

E 2003 Nordson Corporation Part 775160B Specifications 8-1

Section 8 Specifications

Power Supply

Table 8-1 Power Supply Specifications Item Specification Dimensions length 753 mm (29.65 in.) width 465.5 mm (18.33 in.) height 256.3 mm (10.09 in.) Weight 105 kg (230 lb) Voltage 380/440/480 Vac, 3 , 50/60 Hz Current Refer to Table 8-2 Ambient Temperature 13-49 _C (55-120 _F)

Table 8-2 Power Line Current Line 60 Hz 50 Hz Amps @ Amps @ Amps @ Amps @ Amps @ Amps @ 380 Vac 440 Vac 480 Vac 380 Vac 440 Vac 480 Vac L1 14 13 12 16 15 14 L2 22 21 18 25 23 21 L3 13 13 12 16 15 14

E 2003 Nordson Corporation Part 775160B 8-2 Specifications

Lamphead

Table 8-3 Lamphead Specifications Item Specification Dimensions length 264.50 mm (10.41 in.) width 201.00 mm (7.91 in.) height 435.10 mm (17.13 in.) Weight 17 kg (38 lb) High Voltage Power 5000 Vdc @ 850 ma Filament Voltage 3.4 Vac 2 Cooling Air 350 cfm @ 7 in. H2O; measured at lamphead (595 m @1780 Pascal) Reflector Borosilicate glass with dichroic coating 220-470 nm; focus/flood profiles Focal Length Variable Interlocks Photo resistor assembly (light detector) Air pressure switch High-voltage cable connection

Bulb

Table 8-4 Bulb Specifications Item Specification Length 254 mm (10 in.) Power 600 watts/in. maximum Types Mercury, Mercury +, Iron, Gallium, Indium

RF Detector

Table 8-5 RF Detector Specifications Item Specification RF Level Trip Level 2 mW/cm2 Acceptable Level 5 mW/cm2 ANSI Standard C95.1-1982 OSHA Standard 29 CFR 1910.97

Part 775160B E 2003 Nordson Corporation Specifications 8-3

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E 2003 Nordson Corporation Part 775160B 8-4 Specifications

System Drawings See Figures 8-1 through Figure 8-5 for the following system drawings.

Figure 8-1: PC9 Phase Control

Figure 8-2: UV Connector Board

Figure 8-3: System Schematic

Figure 8-4: Lamphead Dimensions

Figure 8-5: System Installation

Part 775160B E 2003 Nordson Corporation Specifications 8-5

1500008A Figure 8-1 PC9 Phase Control

E 2003 Nordson Corporation Part 775160B Specifications 8-6

NOT USED

1500009A

Figure 8-2 UV Connector Board

E 2003 Nordson Corporation Part 775160B Specifications 8-7

1500097A

Figure 8-3 System Schematic

E 2003 Nordson Corporation Part 775160B Specifications 8-8

1500096A

Figure 8-4 Lamphead Dimensions

E 2003 Nordson Corporation Part 775160B Specifications 8-9 FAULT UNIT/ALL MASTER/SLAVE RE DET/NONE LOCK LOCAL

1

4 3 LOC LKOUT/NORMAL REM ANALG EN/DIS FAULT ALL/UNIT SLAVE/MASTER 2

NONE/RE DET 5 LAMP 6“/10”

2 LOC LKOUT/NORMAL REM ANALG EN/DIS FAULT ALL/UNIT SLAVE/MASTER NONE/RE DET LAMP 6“/10”

1500074A

Figure 8-5 System Installation

E 2003 Nordson Corporation Part 775160B UV Glossary 9-1

Section 9 UV Glossary

absorption Not reflecting. The partial loss in energy that results when light passes through or reflects off a medium.

actinic UV Low-powered UV in the UVC band. Usually powered with several 100-watt power supplies or less instead of several 1000-watt power supplies. Nordson’s UV and CoolWave product lines are much higher in irradiance and energy density than actinic UV products.

additive bulb A mercury bulb that contains metal additives such as iron, gallium, indium, or others. These bulbs produce variations in spectral output as compared to mercury only bulbs.

The state in which two surfaces are stuck together.

arc length The distance measured between the electrodes in a quartz bulb. Also Refer to effective cure length.

ASTM spec D3359-95a Refer to tape test.

ballast An inductive transformer device that stabilizes the amount of current flowing through the bulb so that the power output remains constant.

black light UV Low powered UV composed of wavelengths in the UVA band. Usually powered with several 100-watt power supplies or less instead of several 1000-watt power supplies. Nordson’s UV Star and CoolWave product lines are much higher in irradiance and energy density than black light UV products.

bulb A sealed quartz tube that contains a mixture of inert gas and mercury under medium pressure. Electrode bulbs are fitted with electrical connections at the ends of the bulb. Microwave bulbs contain no electrical connections. The mercury and inert gas are energized (vaporized) by either a voltage arc or microwave energy. The vaporized plasma gas emits UV light.

burn-in period The second stage of the startup process of an electrode UV bulb. The total time that it takes the current and voltage inside the bulb to stabilize during startup.

E 2003 Nordson Corporation Part 775160B 9-2 UV Glossary

capacitor Corrects the power factor in the main power supply to reduce current levels in the UV system.

cold mirror A reflector that is coated with a dichroic material that absorbs or passes wavelengths in the infrared range while reflecting those in the UV range. Refer to dichroic.

cover The upper half of the lamp head assembly or the sheet metal top of the power supply. In the lamp head, the cover contains openings and baffles through which cooling air passes.

cradle Supports the UV bulb and reflector inside an electrode lamp head housing.

cross hatch test Refer to tape test.

cure A UV drying process that occurs through a between a UV or coating and UV light.

cure length Refer to effective cure length.

dichroic A coating designed to pass certain wavelengths and reflect other wavelengths. In UV lamp heads, dichroics are used on reflectors to pass or absorb infrared energy and reflect UV energy.

devitrification The act of making quartz glass opaque and porous through prolonged heating and UV exposure.

doped bulb Refer to additive bulb.

dose (dosage) Refer to energy density.

dose rate (dosage rate) Refer to irradiance.

Dual Concentrated Focus An electrode system where two bulbs and two angled reflectors are (DCF) positioned within one cradle. The UV light in a DCF system is concentrated into a single band of energy.

dynamic exposure Exposure to a varying irradiance. It occurs when a lamp head passes over a substrate without pausing or when a substrate passes under a lamp head without pausing.

Part 775160B E 2003 Nordson Corporation UV Glossary 9-3

dynamic range The span between the minimum irradiance and the maximum irradiance to which a radiometer will accurately respond. Measured in joules/cm5.

effective cure length The length of a bulb that delivers optimal UV output. For electrode bulbs, the effective cure length is always less than the arc length. For microwave bulbs, the effective cure length is the length of the bulb.

electrode The electrical fitting on the inside of an arc bulb. The electrode consists of a tungsten pin surrounded by a tungsten coil and is used to maintain a voltage arc across the bulb. Electrode is also used to refer to the style of bulb or system when differentiating between microwave and electrode bulbs and microwave and electrode systems.

electrodeless A microwave-powered UV system.

The full wavelength range of electromagnetic radiation, including microwave, ultraviolet, visible, and infrared energy.

energy density The total amount of UV energy delivered to a particular area, measured in joules/cm2. Also referred to as total energy. Improperly referred to as dose.

erythermal UV Low-powered UV in the UVC band. Usually powered with several 100-watt power supplies or less instead of several 1000-watt power supplies. Nordson’s UV Star and CoolWave product lines are much higher in irradiance and energy density than erythermal UV products.

flood An unfocused band of UV light that is more evenly and diffusely distributed across the width of the reflector.

flux The flow of , measured in einsteins/second.

focal distance (length) The perpendicular distance from the edge of the lamp head to the point where the UV light emitting from the bulb converges. This is the location of maximum UV concentration.

focus The band where the UV energy reflected from the lamp head is at the highest concentration.

frequency The number of times a periodic wavelength cycle occurs in one second, measured in (Hz).

E 2003 Nordson Corporation Part 775160B 9-4 UV Glossary

gallium A bluish-white metallic element used in additive mercury bulbs. The gallium additive provides a yellowish tint to an unenergized UV bulb and a violet coloration to the UV output. Gallium bulbs have a spectral peak around 417 nm and a spectral concentration between 400 and 450 nm. They are often used when deeper cure is required or with white coatings containing titanium oxides. In some industries, microwave gallium bulbs are referred to as V bulbs.

germicidal UV Low-powered UV in the UVC band. Usually powered with several 100-watt power supplies or less instead of several 1000-watt power supplies. Nordson’s UV Star and CoolWave product lines are much higher in irradiance and energy density than germicidal UV products.

housing The lower half of the lamp head assembly. Its function is to support the cradle.

igniter Refer to starter.

indium A -white metallic element used in additive mercury bulbs. The indium additive provides a yellowish tint to an unenergized UV bulb and a violet coloration to the UV output. Indium is used to shift the spectral output past 400 nm. In some industries, indium bulbs are referred to as Q bulbs.

infrared energy Energy having wavelengths between 1 and 100 µm.

integral cooling fan The bulb-cooling fan when it is mounted to the lamp head. (blower)

integral shutter A shutter assembly that is built into the lamp head. Common designs include a pneumatically actuated clam shell that blocks the light when closed and acts as a reflector when open and a pneumatic slide mechanism that moves the lamp head behind an internal louver when shuttered. Shutters are typically associated with electrode systems.

intensity The amount of UV energy delivered to a particular area per unit time, measured in joules/cm2/sec or watts/cm2/sec. Also referred to as watt density. Improperly referred to as dose rate.

iron A white metallic element used in additive mercury bulbs. The iron provides a reddish tint to an unenergized UV bulb and a bluish coloration to the UV output. Iron is used to concentrate the spectral output between 350 and 400 nanometers. In some industries, iron bulbs are referred to as D bulbs.

irradiance Radiant power arriving at a surface from all forward angles per unit area, measured in watts/cm2.

Part 775160B E 2003 Nordson Corporation UV Glossary 9-5

irradiator Refer to lamp head.

joule Metric unit for measuring work or energy. One joule is equivalent to the work done by a force of one Newton acting through a distance of one meter. (1 KW-hour equals 3.6 x 106 joules).

lamp Refer to bulb.

lamp head Assembly containing a sheet metal housing and cover and integral or remote cooling fan. An electrode system also contains cradles and a microwave system contains magnetrons, a cavity, and a screen.

light detector A photocell inside a microwave lamp head that confirms UV output.

long UV Refer to UVA.

louver A part of a UV shutter system or shielding section that blocks the UV light while allowing cooling air to pass through.

magnetron Assembly contained inside a microwave lamp head that converts high-voltage electrical input into RF energy.

mercury A silver-white metallic element that is liquid at room temperature and is used to create a vaporized, UV-emitting gas plasma inside a quartz tube when it is energized through the use of either a voltage arc or microwave energy. When energized the bulb produces a bright white UV output. Mercury bulbs have a peak spectral output around 365 nm and a concentration around 254 nm. In some industries, mercury bulbs are referred to as H bulbs.

mercury plus (H+) Microwave bulbs that contain additional mercury. Mercury plus bulbs are only available in microwave systems as it is difficult to vaporize the additional mercury in an electrode bulb.

mercury arc An electric discharge passed between two electrodes and through a mercury vapor medium inside a quartz tube.

metal halide bulb Refer to additive bulb.

micrometer (mm) Unit of length equivalent to one millionth of a meter.

microwave That part of the electromagnetic spectrum associated with the larger infrared waves and the shorter radio waves.

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monomers A molecule of relatively low molecular weight and simple structure capable of combining with itself or other similar molecules to form .

nanometer (nm) Unit of length equivalent to one billionth of a meter.

negative cooling When the cooling air for the lamp head is drawn from the area surrounding the substrate being cured and through the lamp head. Negative cooling provides exhaust for the UV system if it is ducted to atmosphere. Negative cooling is most often supplied through a remote cooling fan.

blanketing Refer to nitrogen inerting.

nitrogen inerting When the coating or ink is flooded with a nitrogen blanket to prevent the coating or ink from oxidizing before cure. Nitrogen inertion reduces oxygen inhibition.

oligomers A low molecular weight resin or used in a radiation curable coating.

out-of-focus When a lamp head is located further away from the substrate or closer to the substrate than the focal distance.

oxidizing When the coating or ink reacts with oxygen and slows the process of the cure.

oxygen inhibition Oxygen slows the cure response of UV curable coatings. The higher the ratio of exposed surface area to coating mass, the greater the impact oxygen has on the coating.

ozone (O3) An unstable, colorless gas with a penetrating odor that is generated by the reaction of short-wave UV light (≈184 nanometers) with air.

ozone-inhibiting Bulbs where the quartz is manufactured with an additive that prevents (ozone-free) bulbs the transmission of UV beneath 200 nm in wavelength. It is the reaction of short-wave UV light (≈184 nanometers) with air that produces ozone.

Parts Per Million (PPM) The units of the Threshold Limit Value (TLV) when referring to the maximum level of a substance that a person should inhale over an 8-hour shift during a 40-hour week without producing an ill effect. Also refer to Threshold Limit Value.

peak irradiance (peak The maximum irradiance measured over a sample period, measured power density) in joules/cm2/sec or watts/cm2.

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photoinitiator A molecule which when exposed to a specific wavelength of energy forms a reaction that begins the cure process.

photopolymerization Turning a liquid (wet) into a (dry) through exposure to UV light.

planar shutter A shutter assembly that is attached to the outside of a lamp head. The louvered shutter moves perpendicular to the emitted UV light.

polymer A macromolecule consisting of a large number of monomer units.

positive cooling When the cooling air for the lamp head is blown through the lamp head and onto the substrate being cured. Positive cooling can be supplied through either an integral or remote cooling fan. With positive cooling, an additional exhaust system is required to remove heat and ozone.

post cure The continuation of chemical reactions in the ink or coating after exposure to UV has ceased.

power density Refer to irradiance.

quartz plate Plates that allow UV energy to penetrate with minimal loss in intensity and are mounted in front of the lamp head. The plates are used to prevent positive cooling air and airborne contaminants from contacting the substrate, negative cooling air from contaminating the bulb and reflectors, or to remove some of the infrared that is radiated from the UV bulb. If the goal is to reduce the amount of heat contacting the substrate, additional cooling air must be blown across the quartz. If additional air is not used, the quartz will eventually heat up and begin radiating heat onto the substrate. To further reduce heat, the quartz can be coated with a material that passes UV light and absorbs infrared energy.

quartz tube (1) A sealed tube made from a silicate material that is filled with a precise mixture of mercury and various inert gases and sometimes fitted with electrical connections. The vapor emits light when it is energized through the use of either a voltage arc or microwave energy. Often used to refer to the bulb. (2) An open tube made from a silicate material through which a substrate can pass. The tube is often placed in front of a UV lamp head and flooded internally with Nitrogen. Parts traveling through the tube are then safeguarded from exposure to the oxygen and ozone in the lamp head cooling air.

E 2003 Nordson Corporation Part 775160B 9-8 UV Glossary

reflector Reflect and concentrate the UV light onto the substrate. Rolled from highly polished aluminum sheet metal or formed from borosilicate into elliptical or parabolic profiles. Elliptical profiles optimize the concentration of UV energy that is reflected by guiding the radiation into a tightly focused UV band while parabolic reflectors result in a flood of UV light. Holes or slots in the reflector allow cooling air to pass through. The holes or slots are engineered for size and location to provide both optimal and balanced airflow across the length of the bulb.

remote cooling fan (blower) The cooling fan when it is mounted separate from the lamp head and ducted in to the lamp head.

RF . Any frequency between normally audible sound waves and the infrared light portion of the spectrum lying between 10 KHz and 1,000,000 MHz.

RF detector Monitors RF levels in the vicinity of the UV system and signals the power supply to shut off the UV if RF levels exceed allowable limits.

screen A wire mesh assembly attached to a microwave lamp head that allows UV to pass through but prevents RF from leaking from the unit.

short UV Refer to UVC.

single An electrode lamphead assembly with a cradle that supports only one bulb and one reflector.

shutter An assembly designed to block UV light while passing cooling air.

solarization The effect of the UV light on the quartz bulb. Over time, UV light and heat will cause the quartz to devitrify or revert back to a crystalline and porous state.

spectral output The various wavelengths of light emitted from a UV bulb.

spectral output efficiency A graph or chart showing the relative concentration of UV at various graph wavelengths for a particular bulb type. Typically, the concentration is provided as a normalized percentage where the energy is integrated over 10-nanometer bands to reduce the difficulty of quantifying the effects of line emission spectra.

starter Used in electrode, ballast-based systems to vaporize the mercury. The starter puts a 3,000-4,000 volt potential across the bulb during start up and has an internal circuit that discontinues the potential when current is established.

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starter bulb Used in the start up of microwave systems to ignite the mercury vapor in the bulb.

static exposure Exposure to a constant irradiance for a controlled period of time.

striking The initial phase of the startup process where the mercury in the bulb is vaporized.

surface cure When the UV material is cured only on the surface exposed to the UV.

tape test for measuring When an X-cut or lattice pattern of 6 or 11 cuts are scratched through adhesion the UV cured material to the substrate. Pressure-sensitive tape is then applied over the cuts and removed. Pulling the tape away from the substrate will reveal the degree of adhesion. If any material between the lines is pulled off with the tape, the adhesion is poor. If the material remains, the adhesion is good. The recommended guidelines for testing and evaluation are documented in the ASTM spec D3359-95a under Methods A and B. Method A employs the X-cut and is used for coatings that are 5 mils or greater. Method B calls for lattice cuts and is recommended for coatings with 0-5 mils of thickness.

through cure When the UV material is cured down to and including the material / substrate interface.

Threshold Limit Value The maximum exposure a person should receive over an 8-hour shift (TLV) during a 40-hour week without producing an ill effect. Often reported in (mg / m3) or ppm.

Time-Weighed Average Refer to Threshold Limit Value (TLV). (TWA)

total energy Refer to energy density.

transmittance The ratio of the passed through a body to the total radiant energy received by the body.

ultraviolet light Radiant energy in the wavelength band of 100 to 400 nanometers.

UVA (315-400 nanometers) The portion of the electromagnetic spectrum ranging between 315 and 400 nm. UVA represents the largest portion of UV energy and is commonly referred to as long UV. UVA is most responsible for skin aging and increased skin pigmentation. UVA is at the lower limit of sensitivity to the human eye.

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UVB (280-315 nanometers) The portion of the electromagnetic spectrum ranging between 280 and 315 nm. UVB is most responsible for reddening and burning of the skin and damage to the eyes.

UVC The portion of the electromagnetic spectrum ranging between 200 and (200-280 nanometers) 280 nm. UVC is typically referred to as short UV.

UVV The portion of the electromagnetic spectrum ranging between 400 and (400-445 nanometers) 445 nm. The V stands for visible UV.

vacuum UV The portion of the electromagnetic spectrum ranging between 100 and (100-200 nanometers) 200 nm. UVV does not transmit in air.

viscocity The state or quality of having a cohesive and sticky fluid consistency.

vitrification The act of changing pure opaque quartz into clear non-porous quartz through a fusion process.

watt One joule per second.

watt density Refer to irradiance.

waveguide Directs microwaves toward the bulb in microwave UV systems.

wavelength The measured cycle length of a wave in the direction of propagation.

Part 775160B E 2003 Nordson Corporation